Client Challenge
At DSI, we are committed to driving process efficiency through our Paperless Factory Solutions. A longtime client of ours, a leading lawn tool manufacturer, came to us in need of digital transformation of many of its current manufacturing processes. Our client expressed the need for Real-Time Data Access for its Fab Deck Welding Process. The previous data tracking system proved to be outdated and inadequate for our client’s large-scale production tracking needs.
The goal of the project was to streamline their production process by collecting and reporting Overall Equipment Effectiveness (OEE) data from their welding and cleaning cells (built via a third party) — bringing a level of automation and real-time visibility essential for today’s competitive manufacturing environment. The implementation of the new OEE system improves machine efficiency, reduces downtime, and optimizes decision-making.
Our Solution
We implemented a PLC routine that allowed the manufacturer to generate and report critical OEE data directly within Ignition. This routine used custom-defined tags, giving our client the flexibility to track their machine performance in real-time, seamlessly without manual disruption.
Initially built in Ignition 7.9, the project was later upgraded to Ignition 8, taking advantage of the web-based Perspective module for real-time, mobile-responsive access.
Key Features:
- Mobile-Responsiveness, Web-Based Application: The new OEE system is accessible across their domain, allowing operations managers to monitor production efficiency anytime, anywhere.
- Self-Service Machine Integration: Empowering the client to easily add new machines and PLC devices to the system, reducing reliance on manual interventions.
- Automated Reporting: Hour-by-hour OEE data is delivered via automated email reports, enabling better decision-making and faster response times to production issues.
The Paperless Advantage
The integration of the new OEE system into the existing welding and cleaning cells significantly reduced the necessity for manual processes, created Real-Time Data Access, and was a significant advancement toward full-scale paperless transformation. With DSI’s Paperless Factory approach, our client now has a smarter, more efficient production workflow, lower operational costs, and the ability to scale their system effortlessly.
This is how we help our partners transition to AI-powered production tracking and drive digital transformation—one solution at a time.
